Method for producing a same pattern using a simple print and device thereof

ABSTRACT

A method for producing a pattern, in particular a wood pattern, on the face of a woodbased-material board. The pattern is preset with the aid of a digital data set and applied to the woodbased-material board via an intaglio printing process. The pattern is covered with at least one synthetic resin layer and pressed with the woodbased-material board. The digital data set is used to produce a sample print by use of an inkjet printing process, which print is used to compare with the pattern print on the woodbased-material board in terms of optical appearance. The materials and/or printing conditions used in the pattern printing and the sample printing are coordinated with one another.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119 of GermanPatent Application No. 10 2006 022 774.3, filed on May 16, 2006, thedisclosure of which is expressly incorporated by reference herein in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a method for producing a same pattern and aninstallation for printing, coating and pressing two different basematerials with the same pattern, which is covered with a synthetic resinand subsequently pressed therewith.

2. Discussion of Background Information

Base materials, in particular woodbased-material boards, provided with apattern, are generally used as surface elements for cladding floors,walls and ceilings. In particular, when woodbased-material boards areused as floor-covering elements, wood grain, tile patterns, parquetimitations and fantasy patterns are used as patterns.

In particular, when the desired patterns are a single-piece production,the purchaser or customer would like to inspect the desired motif on asample or sample workpiece before the entire batch is completed.Conventionally, a so-called proof paper is used for this purpose, i.e.,the desired pattern is printed on a paper with the aid of an inkjetprinter. This proof paper is then assessed for suitability and, if theoutcome is positive, a further data set is produced with which, forinstance, a print roller is produced which is used for the actualprinting process of the pattern when printing the woodbased-materialboard.

However, with this approach the problem is encountered that the proofpaper and the end product, the printed woodbased-material board, canultimately produce a non-identical appearance of the pattern due to thedifferent materials, paper or a woodbased-material board. The reason forthis discrepancy is that, on the one hand, a different ink is used forprinting the proof paper and, on the other hand, the application methodin the form of printed dots (pixels) differs from the application of aprinting ink onto a woodbased-material board generally carried out withthe aid of an anilox roller.

Conventionally, a motif provided by a purchaser is converted into a dataset which already contains a certain number of control parameters tocontrol an inkjet printer. An inkjet printer is now operated with theaid of the data set to print the motif onto a decorative paper. Adecorative paper obtained in this manner is submitted to the purchaserand, if it is approved, the existing data set is used to design afurther data set that is used to engrave a print roller to be used forprinting. An engraving of this type is preferably made with the aid of alaser.

The second data set is therefore already different with which the motifis now printed onto a woodbased-material board using correct printingink, and this board is compared to the proof paper. If the comparisonproves to be negative, and the two prints are not consistent, the dataset is used to start another printing, which may also require one ormore baby rollers to be split off. If a satisfactory printing on awoodbased-material board is now finally achieved, the woodbased-materialboard, e.g., to produce a flooring panel, is provided with anabrasion-resistant layer and pressed in a so-called short-cycle press.

The changes that are inevitably produced during pressing and thepreceding coating necessitate another comparison of the proof paper withthe end result regarding the optical appearance of the motif printed onthe board. If unacceptable deviations are found, another attempt must bemade to match the proof paper and the end result by changing theconditions prevailing during the coating and/or pressing process. Amethod of this type may be very time-consuming as well as ultimatelycost-intensive.

It is known from EP 1 145 863 B1 to produce a sample print on an inkjetprinter. The base material should resemble the gravure paper used forthe serial print in terms of brilliance or degree of brightness andgloss. To this end, regular gravure paper is provided with anink-receiving layer that is as transparent as possible.

It is known from the publication “Farbmanagement und Rastererhalt ineinem Proof” in Druckspiegel (dated January 2003, pages 20 through 22)to control an inkjet printer with the same data set with which aprinting plate is written. A test system of this type is known, e.g., inthe “Digitaler Kontraktproof von Rasterdaten” data sheet.

The advantages and disadvantages of the raster proof, which depend onthe print products and the customer requirements, are discussed in thejournal www.value-magazine.de “Gerasteter Digitalproof,” April 2006.

SUMMARY OF THE INVENTION

The invention ensures that the greatest possible conformity is achievedbetween a sample provided for inspection and a series-manufactured endproject. This is achieved according to the invention through a methodfor producing a same pattern, comprising a plurality of image points, onat least one side of base materials from one original data set. Themethod comprises:

-   -   Printing the pattern on one side of a first base material as a        sample print with an inkjet printer;    -   Covering the pattern with a synthetic resin layer;    -   Pressing the first base material with the pattern and the        synthetic resin layer;    -   Printing the pattern on one side of a second base material by        means of a print roller with a raster in an intaglio printing        process;    -   Covering the pattern with a synthetic resin layer; and    -   Pressing the second base material with the pattern and the        synthetic resin layer.

In this method, the original digital data set is used to control theinkjet printer as well as to produce the print roller, so that when thetwo printed images are compared, the number of image points per unitarea on the first base material is essentially the same as the number ofimage points per unit area on the second base material. The size of theimage points and the nozzle spacing of the inkjet printer arecoordinated with the size of the screen dots and the raster sizes in theintaglio printing process. Identical printing liquids are used for theinkjet print and the intaglio print.

A device is provided for printing, coating and pressing two differentbase materials with the same pattern, which is covered with a syntheticresin and subsequently pressed therewith. The device has a firstprinting line and a second printing line. The pattern is applied to thefirst base material with the aid of an inkjet printer in the firstprinting line, and the same pattern is applied to a second base materialwith the aid of an intaglio printing device in the second printing line.The test unit is provided on an exit side with an optical scan elementand a comparison unit to compare the printing results of the first andsecond printing line with respect to optical appearance.

According to the invention, the sample workpiece used for an initialinspection, the first base material and the series-manufactured endproduct are produced using such materials and/or conditions that lead toan identical or essentially identical result of both printing methodswith respect to optical appearance. The same optical appearance to theobserver of both prints is the decisive factor.

In the invention, a pattern print produced on a second base material byan intaglio printing process is coordinated with a sample print producedon a first base material by an inkjet printing method. The parametersprevailing in the respective printing process and characterizing therespective print with respect to the appearance of the respectiveprinting result are largely matched to one another. To this end, theprint roller has a raster to take up the ink, the size and shape ofwhich raster is responsible for the quantity of ink. Ideally, one screendot corresponds to one image point.

The number of the image points respectively produced per unit area isadjusted in both methods such that a printing result is obtained with anessentially identical appearance. This is carried out by adjusting thesize of the image points and the nozzle spacings of the inkjet printingmethod to the size of the screen dots and the raster sizes in theintaglio printing process. One screen dot ideally corresponds to oneimage point.

The printing liquids or printing inks used are selected such that anessentially identical appearance is produced with both printing methods.To this end, identical printing liquids or printing inks should be used,since otherwise chromatic aberrations, so-called metamers, can occur.Metamers are understood to describe when colors that appear identical ina certain light, prove to be different when the light source changes.This occurs in particular when different pigment combinations are used.By adjusting the respective binders, solvents and pigments anessentially identical printing result is advantageously obtained withrespect to optical appearance with both printing methods. In thismanner, printing result accurate conclusions can be drawn using thesample print regarding the serial printing of the respective pattern tobe anticipated.

Advantageously, the same base material is used for the sample print andthe pattern print so that the comparison of the two printed images withone another is more effective because the same base materials are used.Advantageously woodbased-material, synthetic, stone or linoleum boardscan be used as base materials. However, it is also possible to useconventional decorative papers as a base material.

It has proven to be useful to carry out the step of comparing the resultof the sample print with the actual pattern print after the coating andpressing of the sample print with the carrier in order to be able tocompare a sample print and pattern print as close as possible to aserial printing. In order to obtain the closest possible imitation ofthe natural material, it is advantageous if a surface relief synchronousto the pattern is embossed with the aid of a surface stamping die duringthe pressing the pattern print and the coated sample print with the basematerial. The base material provided with the pattern print and the basematerial provided with the sample print are advantageously provided witha chamfer on at least two opposite edges. Printing the pattern isadvantageously carried out in an indirect intaglio printing process inwhich the printing liquids are applied to the base material indirectlyvia a rubber roll in order to even out irregularities in the basematerial while obtaining a uniform printed image.

It has proven to be possible to produce the print roller for theintaglio printing process with the aid of a laser, an etching process orwith the aid of the erosion process. A particularly precise engraving ofthe print roller can be achieved through these methods.

The device advantageously has a first printing line and a secondprinting line. The pattern is applied to a first base material with theaid of an inkjet printer in the first printing line. The same pattern isapplied to a second base material with the aid of an intaglio printingdevice in the second printing line. A test unit with an optical scanelement and a comparison unit for comparing the printing results of thefirst and second printing line with respect to optical appearance isprovided at the exit side. This renders possible an effective comparisonof the two printing results.

The test device is used for the optical recording of a printed image.The test device uses an optical scan element, which can comprise, e.g.,a CCD element (charge-coupled device). A CCD element is an electroniccomponent that is used in optical devices. With the CCD, the imagestrength can be finely rasterized, measured in a spatially resolvingmanner. The aim is to obtain the most precise image possible forsubsequent storage and reproduction. The comparison unit, e.g., acomputer carries out a comparison of the two printed images via a presetalgorithm to determine the degree of conformity.

It has proven to be advantageous for the optical scan element to containa control unit in which the results obtained in the scanning process canbe compared to a preset data set. If there is conformity or if thedeviations are acceptable, a switching pulse can be transmitted tocontrol the second printing line so that a cost-effective comparison ofthe two printed images is possible. The pattern in the second printingline can be advantageously applied indirectly to the second supportboard via a rubber roll with an indirect printing process in order toeven out irregularities in the support board.

A method for producing a same pattern comprising a plurality of imagepoints on respectively one side of two different base materials from anoriginal digital data set comprises: printing a pattern on one side of afirst base material as a sample print; covering the pattern with asynthetic resin layer; pressing the first base material with the patternand the synthetic resin layer; printing the pattern on one side of asecond base material; covering the pattern on the second base materialwith a synthetic resin layer; and pressing the second base material withthe pattern and the synthetic resin layer. The original digital data setcontrols the printing on the first base material and the second basematerial so that a number of image points per unit area on the firstbase material essentially corresponds to a number of image points perunit area on the second base material. A size of the image points andnozzle spacings of the printing on the first base material arecoordinated with a size of screen dots and raster sizes in a printingprocess of the second based material. Identical printing liquids areused for the printing of the pattern on the first base material and thesecond based material.

A further method of printing comprises: providing a pattern in a form oforiginal data; generating a data set used in a printing processgenerated from the original data; printing a first material board usingthe data set; coating the first material board with at least a firstsynthetic resin-based layer; pressing the at least first synthetic resinlayer with the printed first material board in a short-cycle press;generating a further data set from the original data as the basis for anindirect printing process; adding control parameters for controlling alaser to the original data; and engraving a print roller according tothe original data with aid of the control parameters. The further dataset and the data set are analogously generated from the original data byaddition of respective corresponding control parameters. The methodfurther comprises printing the pattern on one side of a second materialboard with the print roller using the further data set; covering thepattern on the second material board with a synthetic resin layer; andpressing the second material board with the pattern and the syntheticresin layer.

In aspect of the invention, the method further includes providing apattern is obtained by photographing an original pattern by a digitalcamera. The at least first synthetic resin layer contains melamine resinor resinous resin. The at least first synthetic resin layer containsembedded corundum particles. The data set contains additional controldata or control parameters to control inkjet nozzles. The original datacontrols the printing on the first material board and the secondmaterial board so that a number of image points per unit area on thefirst material board essentially corresponds to a number of image pointsper unit area on the second material boar. A size of the image pointsand nozzle spacings of the printing on the first material board arecoordinated with a size of screen dots and raster sizes in a printingprocess of the second material board. Identical printing liquids areused for the printing of the pattern on the first material board and thesecond material board.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention,in which like reference numerals represent similar parts throughout theseveral views of the drawings, and wherein:

FIGS. 1 a-d represent a process flow and device according to theinvention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

Referring to FIG. 1 a, a pattern, e.g., in the form of a wood grain, isprovided in the form of original data 1 obtained by photographing anoriginal pattern by a digital camera. A data set 4 that can be used inan inkjet printer 3 is generated from the original data 1 with the aidof an electronic device 2. In addition to the original data 1, the dataset 4 contains additional control data or control parameters 4 a tocontrol inkjet nozzles. A woodbased-material board 5 is now printed withthe aid of the inkjet printer.

A printing ink suitable for series production is used as a printingmedium. Within the scope of the invention, the ink withstands the highpressure and the temperature stresses in the pressing operation of thewoodbased-material board in a short-cycle press as is known in the art.After printing, the woodbased-material board 5 is coated with a firstsynthetic resin-based layer that preferably contains melamine resin orresinous resin. According to the invention, corundum particles areembedded in this first layer to establish the desiredabrasion-resistance.

Another likewise synthetic resin-based finish coating is applied to thefirst layer. The synthetic resin layers are pressed with the printedwoodbased-material board 5 in a short-cycle press in a manner known tothose of ordinary skill in the art. The product thus obtained, havingsmall dimensions of preferably board lengths between 1 to 2 m and boardwidths of the same kind, can now be studied with regard to its opticalappearance.

Referring to FIG. 1 b, if the pattern applied with the aid of the inkjetprinter 3 meets the requirements of the purchaser or customer, a furtherdata set 6 can be generated from the original data 1 according to thedata set 4 as the basis for an indirect intaglio printing process. Thisprovides advantages in particular if woodbased-material boards providedwith the desired pattern are to be produced in large production runs.

As further shown in FIG. 1 b, control parameters 6 a for controlling alaser 8 (see, FIG. 1 c) are added to the original data 1 with anelectronic, preferably computer-operated read/write device shown byreference number 7 in a general manner. As further shown in FIG. 1 c, aprint roller 9 is engraved according to the original data 1 with the aidof the control parameters 6 a. According to the invention the furtherdata set 6 as well as the data set 4 are analogously generated from theoriginal data 1 by addition of the respective corresponding controlparameters.

After the completion of the print roller 9 by engraving, e.g., laserengraving, the printing of large sized woodbased-material boards 10 iscarried out as shown in FIG. 1 d. This printing can be carried out in aconventional intaglio printing process using a printing ink used in theinkjet printing process and a corresponding printing color in terms ofthe optical image in a series production installation. The patterncorresponding to the original data 1 is applied via a form roller 11. Aconformity in terms of optical appearance is thus ensured according tothe invention between the woodbased-material board 5 produced forinspecting a small production run (sample run) of approximately one toten and with small dimensions and the woodbased-material boards 10provided with the same pattern in a series production process.

As should be understood, the original digital data set controls theprinting on the first base material and the second base material so thata number of image points per unit area on the first base materialessentially corresponds to a number of image points per unit area on thesecond base material. Also, a size of the image points and nozzlespacings of the printing on the first base material are coordinated witha size of screen dots and raster sizes in a printing process of thesecond based material, and identical printing liquids are used for theprinting of the pattern on the first base material and the second basedmaterial.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

What is claimed:
 1. A method for producing a same pattern comprising aplurality of image points on respectively one side of two different basematerials from an original digital data set comprising: printing apattern on one side of a first base material as a sample print with aninkjet printer; covering the pattern with a synthetic resin layer;pressing the first base material with the pattern and the syntheticresin layer; printing the pattern on one side of a second base materialby use of a print roller with a raster in an intaglio printing process;covering the pattern on the second base material with a synthetic resinlayer; pressing the second base material with the pattern and thesynthetic resin layer, wherein the original digital data set controlsthe inkjet printer and produces the print roller so that a number ofimage points per unit area on the first base material essentiallycorresponds to a number of image points per unit area on the second basematerial and a size of the image points and nozzle spacings of theinkjet printer are coordinated with a size of screen dots and rastersizes in the intaglio printing process, and identical printing liquidsare used for the printing of the pattern on the first base material andthe second based material.
 2. The method according to claim 1, whereinidentical solvents, pigments and binders are used for printing liquids.3. The method according to claim 1, wherein a woodbased-material board,a plastic board, a stone slab, a linoleum board or a decorative paper isused as a base material.
 4. The method according to claim 3, wherein asurface structure synchronous to the pattern is embossed during thepressing of the first and second base materials with the pattern and thesynthetic resin layer.
 5. The method according to claim 3, wherein thefirst base material and the second base material are provided with achamfer on at least two opposite edges.
 6. The method according to claim1, wherein the raster of the print roller for intaglio printing isproduced by a laser, an etching process or an erosion process.
 7. Themethod according to claim 6, wherein the printing of the pattern on thesecond base material is carried out in an indirect intaglio printingprocess.
 8. The method according to claim 1, wherein the pattern isobtained by photographing an original pattern by a digital camera. 9.The method according to claim 8, wherein a data set for printing on thefirst base material is obtained by the original digital data set and isused in an inkjet printer.
 10. The method according to claim 9, whereinthe original data set contains additional control data to control inkjetnozzles.
 11. The method according to claim 10, wherein the first basematerial is a woodbased-material board printed with aid of an inkjetprinter.
 12. The method according to claim 11, wherein the printingliquids withstand pressure and temperature stresses in a pressingoperation of the woodbased-material board in a short-cycle press. 13.The method according to claim 12, wherein after printing of the firstbase material, the woodbased-material board is coated with a firstsynthetic resin-based layer that contains melamine resin or resinousresin.
 14. The method according to claim 13, wherein corundum particlesare embedded in the first synthetic resin-based layer to establishabrasion-resistance.
 15. The method according to claim 14, whereinanother synthetic resin-based finish coating is applied to the firstsynthetic resin-based layer.
 16. The method according to claim 15,wherein if the pattern applied with the aid of the inkjet printer meetsrequirements, a further data set is generated from the original data setas a basis for an indirect intaglio printing process.
 17. The methodaccording to claim 16, wherein a print roller is engraved according tothe original data set with aid of control parameters.
 18. The methodaccording to claim 17, wherein printing using the print roller printingis carried out in a intaglio printing process using a printing ink usedin the inkjet printing process.